1999 SUBARU LEGACY Service Repair Manual

F: CLEANING AND REGAPPING
Clean spark plugs in a sand blast type cleaner.
Avoid excessive blasting. Clean and remove car-
bon or oxide deposits, but do not wear away por-
celain.
If deposits are too stubborn, discard plugs.
After cleaning spark plugs, recondition firing sur-
face of electrodes with file. Then correct the spark
plug gap using a gap gauge.
Spark plug gap: L
1.0 Ð 1.1 mm (0.039 Ð 0.043 in)
G6M0091
4. Ignition Coil and Ignitor
Assembly (2200 cc Model)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G6M0095
2) Disconnect spark plug cords from ignition coil
and ignitor assembly.
3) Disconnect connector from ignition coil and
ignitor assembly.
B6M0932
4) Remove ignition coil and ignitor assembly.
B6M0930
5) Installation is in the reverse order of removal.
CAUTION:
Be sure to connect wires to their proper posi-
tions. Failure to do so will damage unit.
34
6-1[W3F0]SERVICE PROCEDURE
4. Ignition Coil and Ignitor Assembly (2200 cc Model)

B: INSPECTION
Using accurate tester, inspect the following items,
and replace if defective.
1) Primary resistance
2) Secondary coil resistance
CAUTION:
If the resistance is extremely low, this indicates
the presence of a short-circuit.
Specified resistance:
[Primary side]
Between terminal No. 1 and No. 2
0.73
W±10%
Between terminal No. 2 and No. 4
0.73
W±10%
B6M0931A
[Secondary side]
Between (A) and (B)
12.8 k
W±15%
Between (C) and (D)
12.8 k
W±15%
B6M0773C
3) Insulation between primary terminal and case:
10 MWor more.
5. Ignition Coil (2500 cc Model)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
B2M1723
2) Disconnect spark plug cords from ignition coil.
3) Disconnect connector from ignition coil.
B6M0772
4) Remove ignition coil.
B6M0867
5) Installation is in the reverse order of removal.
CAUTION:
Be sure to connect wires to their proper posi-
tions. Failure to do so will damage unit.
35
[W5A0]6-1SERVICE PROCEDURE
5. Ignition Coil (2500 cc Model)

B: INSPECTION
Using accurate tester, inspect the following items,
and replace if defective.
1) Primary resistance
2) Secondary coil resistance
CAUTION:
If the resistance is extremely low, this indicates
the presence of a short-circuit.
Specified resistance:
[Primary side]
Between terminal No. 1 and No. 2
0.73
W±10%
Between terminal No. 2 and No. 4
0.73
W±10%
B6M0931A
[Secondary side]
Between (A) and (B)
12.8 k
W±15%
Between (C) and (D)
12.8 k
W±15%
B6M0773C
3) Insulation between primary terminal and case:
10 MWor more.
5. Ignition Coil (2500 cc Model)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
B2M1723
2) Disconnect spark plug cords from ignition coil.
3) Disconnect connector from ignition coil.
B6M0772
4) Remove ignition coil.
B6M0867
5) Installation is in the reverse order of removal.
CAUTION:
Be sure to connect wires to their proper posi-
tions. Failure to do so will damage unit.
35
[W5A0]6-1SERVICE PROCEDURE
5. Ignition Coil (2500 cc Model)

B: INSPECTION
Using accurate tester, inspect the following items,
and replace if defective.
1) Primary resistance
2) Secondary coil resistance
CAUTION:
If the resistance is extremely low, this indicates
the presence of a short-circuit.
Specified resistance:
[Primary side]
Between terminal No. 1 and No. 2
0.73
W±10%
Between terminal No. 2 and No. 3
0.73
W±10%
B6M0774B
[Secondary side]
Between (A) and (B)
12.8 k
W±15%
Between (C) and (D)
12.8 k
W±15%
B6M0773C
3) Insulation between primary terminal and case:
10 MWor more.
6. Ignitor (2500 cc Model)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G6M0095
2) Disconnect connector from ignitor.
B6M0161
3) Remove screws which hold ignitor onto body.
4) Installation is in the reverse order of removal.
36
6-1[W5B0]SERVICE PROCEDURE
6. Ignitor (2500 cc Model)

B: INSPECTION
Using accurate tester, inspect the following items,
and replace if defective.
1) Primary resistance
2) Secondary coil resistance
CAUTION:
If the resistance is extremely low, this indicates
the presence of a short-circuit.
Specified resistance:
[Primary side]
Between terminal No. 1 and No. 2
0.73
W±10%
Between terminal No. 2 and No. 3
0.73
W±10%
B6M0774B
[Secondary side]
Between (A) and (B)
12.8 k
W±15%
Between (C) and (D)
12.8 k
W±15%
B6M0773C
3) Insulation between primary terminal and case:
10 MWor more.
6. Ignitor (2500 cc Model)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G6M0095
2) Disconnect connector from ignitor.
B6M0161
3) Remove screws which hold ignitor onto body.
4) Installation is in the reverse order of removal.
36
6-1[W5B0]SERVICE PROCEDURE
6. Ignitor (2500 cc Model)

7. Spark Plug Cord
A: INSPECTION
1. 2200 cc MODEL
Check for:
1) Damage to cords, deformation, burning or rust
formation of terminals
2) Resistance values of cords
Resistance value:
5.12 Ð 12.34 k
W
B6M0775
2. 2500 cc MODEL
Check for:
1) Damage to cords, deformation, burning or rust
formation of terminals
2) Resistance values of cords
Resistance value:
#1 and #3
6.43 Ð 15.01 k
W
B6M0868
#2 and #4
6.67 Ð 15.57 k
W
B6M0869
37
[W7A2]6-1SERVICE PROCEDURE
7. Spark Plug Cord

1. Starter
Trouble Probable cause
Starter does not start.Magnet switch does not operate.
(no clicks are heard.)Magnet switch poor contact or disconti-
nuity of pull-in coil circuit
Improper sliding of magnet switch
plunger
Magnet switch operates.
(clicks are issued.)Poor contact of magnet switch's main
contact point
Layer short of armature
Contaminants on armature commutator
High armature mica
Improper grounding of yoke field coil
Insufficient carbon brush length
Insufficient brush spring pressure
Starter starts but does not crank engine.Failure of pinion gear to engage ring
gearWorn pinion teeth
Improper sliding of overrunning clutch
Improper adjustment of stud bolt
Clutch slippage Faulty clutch roller spring
Starter starts but engine cranks too slowly.Poor contact of magnet switch's main
contact point
Layer short of armature
Discontinuity, burning or wear of arma-
ture commutator
Poor grounding of yoke field coil
Insufficient brush length
Insufficient brush spring pressure
Abnormal brush wear
Starter overruns. Magnet switch coil is a layer short.
38
6-1[K100]DIAGNOSTICS
1. Starter

2. Generator
B6M0771
39
[K200]6-1DIAGNOSTICS
2. Generator